Smoking Substitute Consumable

ABSTRACT

The present disclosure relates to an aerosol-forming article comprising: an aerosol-forming substrate; and a filter element having a hollow bore extending from the downstream axial end of the substrate to the downstream axial end of the article.

This application is a non-provisional application claiming benefit tothe international application no. PCT/EP2019/079186 filed on Oct. 25,2019, which claims priority to GB 1817578.6 filed on Oct. 29, 2018. Thisapplication also claims benefit to the international application no.PCT/EP2019/079187 filed on Oct. 25, 2019, which claims priority to GB1817560.4 filed on Oct. 29, 2018.

FIELD OF THE DISCLOSURE

The present disclosure relates to a consumable for use in a smokingsubstitute system and particularly, although not exclusively, to aheat-not-burn (HNB) consumable. The present disclosure also relates to aconsumable wherein the consumable comprises a substrate comprising agathered web of plant material; a method of forming the web of plantmaterial; and a method for forming the article.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker topotentially harmful substances. It is generally thought that asignificant amount of the potentially harmful substances are generatedthrough the heat caused by the burning and/or combustion of the tobaccoand the constituents of the burnt tobacco in the tobacco smoke itself.

Conventional combustible smoking articles, such as cigarettes, typicallycomprise a cylindrical rod of tobacco comprising shreds of tobacco whichis surrounded by a wrapper, and usually also a cylindrical filteraxially aligned in an abutting relationship with the wrapped tobaccorod. The filter typically comprises a filtration material which iscircumscribed by a plug wrap. The wrapped tobacco rod and the filter arejoined together by a wrapped band of tipping paper that circumscribesthe entire length of the filter and an adjacent portion of the wrappedtobacco rod. A conventional cigarette of this type is used by lightingthe end opposite to the filter, and burning the tobacco rod. The smokerreceives mainstream smoke into their mouth by drawing on the mouth endor filter end of the cigarette.

Combustion of organic material such as tobacco is known to produce tarand other potentially harmful by-products. There have been proposedvarious smoking substitute systems (or “substitute smoking systems”) inorder to avoid the smoking of tobacco.

Such smoking substitute systems can form part of nicotine replacementtherapies aimed at people who wish to stop smoking and overcome adependence on nicotine.

Smoking substitute systems include electronic systems that permit a userto simulate the act of smoking by producing an aerosol (also referred toas a “vapor”) that is drawn into the lungs through the mouth (inhaled)and then exhaled. The inhaled aerosol typically bears nicotine and/orflavorings without, or with fewer of, the odor and health risksassociated with traditional smoking.

In general, smoking substitute systems are intended to provide asubstitute for the rituals of smoking, whilst providing the user with asimilar experience and satisfaction to those experienced withtraditional smoking and with combustible tobacco products. Some smokingsubstitute systems use smoking substitute articles that are designed toresemble a traditional cigarette and are cylindrical in form with amouthpiece at one end.

The popularity and use of smoking substitute systems has grown rapidlyin the past few years. Although originally marketed as an aid to assisthabitual smokers wishing to quit tobacco smoking, consumers areincreasingly viewing smoking substitute systems as desirable lifestyleaccessories.

There are a number of different categories of smoking substitutesystems, each utilizing a different smoking substitute approach.

One approach for a smoking substitute system is the so-called “heat notburn” (“HNB”) approach in which tobacco (rather than an “e-liquid”) isheated or warmed to release vapor. The tobacco may be leaf tobacco orreconstituted tobacco. The vapor may contain nicotine and/or flavorings.In the HNB approach the intention is that the tobacco is heated but notburned, i.e., the tobacco does not undergo combustion.

A typical HNB smoking substitute system may include a device and aconsumable. The consumable may include the tobacco material. The deviceand consumable may be configured to be physically coupled together. Inuse, heat may be imparted to the tobacco material by a heating elementof the device, wherein airflow through the tobacco material causesmoisture in the tobacco material to be released as vapor. A vapor mayalso be formed from a carrier in the tobacco material (this carrier mayfor example include propylene glycol and/or vegetable glycerin) andadditionally volatile compounds released from the tobacco. The releasedvapor may be entrained in the airflow drawn through the tobacco.

In general, the heating element may only come into contact with aportion of the tobacco material in a consumable. Those portions of thetobacco material that are close to, or in contact with, the heatingelement may heat up more quickly, and may have a higher temperature,than other portions of the tobacco. In some cases, it may be desirableto control the distribution of heat throughout the tobacco material.

As the vapor passes through the consumable (entrained in the airflow)from an inlet to a mouthpiece (outlet), the vapor cools and condenses toform an aerosol for inhalation by the user. The aerosol will normallycontain the volatile compounds.

In HNB smoking substitute systems, heating as opposed to burning thetobacco material is believed to cause fewer, or smaller quantities, ofthe more harmful compounds ordinarily produced during smoking.Consequently, the HNB approach may reduce the odor and/or health risksthat can arise through the burning, combustion and pyrolytic degradationof tobacco.

In some cases, the aerosol passing from the mouthpiece (i.e., beinginhaled by a user) may not be in a desirable state. Thus, it may bedesirable to alter one or more characteristics of the aerosol before itis inhaled by the user.

There is a need for an improved design of HNB consumables to enhance theuser experience and improve the function of the HNB smoking substitutesystem.

The present disclosure has been devised in the light of the aboveconsiderations.

SUMMARY OF THE DISCLOSURE

First Mode: A Consumable Having an Axial Bore Extending from anAerosol-Forming Substrate to the Downstream Axial End of the Article

At its most general, a first mode of the present disclosure relates toan aerosol-forming article, e.g., a smoking substitute article such asan HNB consumable having an axial bore extending from an aerosol-formingsubstrate to the downstream axial end of the article.

According to a first aspect of the first mode, there is provided anaerosol-forming article (e.g., a smoking substitute article such as anHNB consumable) comprising an aerosol-forming substrate and a filterelement having a hollow bore extending from the downstream axial end ofthe substrate to the downstream axial end of the article.

By providing an aerosol-forming article having only two axialcomponents, the complexity of the manufacture of the article issignificantly reduced thus reducing manufacturing times, cost andtolerances. The axial bore extending from the downstream axial end ofthe substrate to the axial downstream (mouth) end of the articleprovides a space for mixing and cooling of the vapor/aerosol generatedby heating of the substrate and also provides passage of low resistanceto help reduce condensation and maximize visible vapor.

Optional features will now be set out. These are applicable singly or inany combination with any aspect of the first mode.

The aerosol-forming article is preferably a heat-not-burn (HNB)consumable.

The aerosol-forming substrate is capable of being heated to release atleast one volatile compound that can form an aerosol. Theaerosol-forming substrate may be located at the upstream end of thearticle/consumable.

As used herein, the terms “upstream” and “downstream” are intended torefer to the flow direction of the vapor/aerosol, i.e., with thedownstream end of the article/consumable being the mouth end or outletwhere the aerosol exits the article/consumable for inhalation by theuser. The upstream end of the article/consumable is the opposing end tothe downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprisesat least one volatile compound that is intended to bevaporized/aerosolized and that may provide the user with a recreationaland/or medicinal effect when inhaled. Suitable chemical and/orphysiologically active volatile compounds include the group consistingof: nicotine, cocaine, caffeine, opiates and opioids, cathine andcathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorinA together with any combinations, functional equivalents to, and/orsynthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plantmaterial may comprise least one plant material selected from the listincluding Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry),Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galeazacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura),Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisusscoparius, Damiana, Entada rheedii, Eschscholzia californica (CaliforniaPoppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica(Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium),Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort),Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata(Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip),Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaeacaerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower),Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica(Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage),Salvia species (Sage), Scutellaria galericulata, Scutellarialateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sidaacuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum(Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus,Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (MaconhaBrava) together with any combinations, functional equivalents to, and/orsynthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may beused. This includes, but is not limited to, flue-cured tobacco, burleytobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco,dark-fired tobacco, perique tobacco and rustica tobacco. This alsoincludes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includesleaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco,tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco,homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobaccoand/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet ofhomogenised (e.g., paper/slurry recon) tobacco or gathered shreds/stripsformed from such a sheet.

In some embodiments, the sheet used to form the aerosol-formingsubstrate has a gra mm age greater than or equal to 100 g/m2, e.g.,greater than or equal to 110 g/m2 such as greater than or equal to 120g/m2.

The sheet may have a gra mm age of less than or equal to 300 g/m2, e.g.,less than or equal to 250 g/m2 or less than or equal to 200 g/m2.

The sheet may have a gra mm age of between 120 and 190 g/m2.

The aerosol-forming substrate may comprise at least 50 wt % plantmaterial, e.g., at least 60 wt % plant material, e.g., around 65 wt %plant material. The aerosol-forming substrate may comprise 80 wt % orless plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additivesselected from humectants, flavorants, fillers, aqueous/non-aqueoussolvents and binders.

Humectants are provided as vapor generators—the resulting vapor helpscarry the volatile active compounds and increases visible vapor.Suitable humectants include polyhydric alcohols (e.g., propylene glycol(PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG))and their esters (e.g., glycerol mono-, di- or tri-acetate). They may bepresent in the aerosol-forming substrate in an amount between 1 and 50wt %.

The humectant content of the aerosol-forming substrate may have a lowerlimit of at least 1% by weight of the plant material, such as at least 2wt %, such as at least 5 wt %, such as at least 10 wt %, such as atleast 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upperlimit of at most 50% by weight of the plant material, such as at most 40wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-formingsubstrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together thecomponents forming the aerosol-forming substrate. Binders may comprisestarches and/or cellulosic binders such as methyl cellulose, ethylcellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methylcellulose, gums such as xanthan, guar, arabic and/or locust bean gum,organic acids and their salts such as alginic acid/sodium alginate, agarand pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-formingsubstrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen theaerosol-forming substrate. Fillers may comprise fibrous (non-tobacco)fillers such as cellulose fibres, lignocellulose fibres (e.g., woodfibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-formingsubstrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueoussolvent. In some embodiments, the aerosol forming substrate has a watercontent of between 5 and 10 wt %, e.g., between 6-9 wt % such as between7-9 wt %.

The flavorant may be provided in solid or liquid form. It may includementhol, liquorice, chocolate, fruit flavor (including, e.g., citrus,cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobaccoflavor. The flavorant may be evenly dispersed throughout theaerosol-forming substrate or may be provided in isolated locationsand/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantiallycylindrical shape such that the article/consumable resembles aconventional cigarette. It may have a diameter of between 5 and 10 mm,e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may havean axial length of between 10 and 15 mm, e.g., between 11 and 14 mm suchas around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by awrapping layer, e.g., a paper wrapping layer. The wrapping layer mayoverlie an inner foil layer or may comprise a paper/foil laminate (withthe foil innermost).

The article/consumable comprises a filter element extending from thedownstream axial end of the substrate to the downstream axial end of thearticle.

The filter element may be at least partly (e.g., entirely) circumscribedby the (paper) wrapping layer.

The filter element may be comprised of cellulose acetate orpolypropylene tow. The filter element may be comprised of activatedcharcoal. The filter element may be comprised of paper. The filterelement may be comprised of plant material, e.g., extruded plantmaterial. The filter element may be circumscribed with a plug wrap,e.g., a paper plug wrap (which will itself be circumscribed by thewrapping layer).

The filter element may have a substantially cylindrical shape with adiameter substantially matching the diameter of the aerosol-formingsubstrate (i.e. between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8mm, e.g., around 7 mm). The axial length of the filter element may beless than 50 mm and greater than 20 mm, e.g., between 25 and 45 mm, forexample between 30 and 40 mm, e.g., between 33 and 38 mm, such as around36 mm.

The hollow bore through the filter element may be uniform along itsaxial length with a bore diameter of between 1 and 5 mm, e.g., between 2and 4 mm or between 2 and 3 mm.

The hollow bore through the filter element may vary along the axiallength. For example, there may a stepped variation in bore diameteralong its axial length. In some embodiments, the filter elementcomprises a plurality of portions wherein at least one of the portionshas a different bore diameter than the other filter portions. Theportions are unified to form the unitary filter element.

For example, there may be an upstream filter portion and a terminalfilter portion. In some embodiments, the bore diameter of the upstreamfilter portion is greater than the bore diameter of the terminal filterportion. For example, the upstream filter portion may have a borediameter that is 0.5 mm or more, or 1 mm or more than the bore diameterof the terminal filter portion. For example, the upstream filter portionmay have a bore diameter of between 3 and 5 mm. The terminal filterportion may have a bore diameter of between 1 and 2 mm.

In some embodiments, the bore diameter of the upstream and terminalfilter portions may be equal.

There may be an intermediate filter portion axially interposed andadjacent the upstream and terminal filter portions. The diameter of thebore within the intermediate portion is preferably larger than thediameter in both the upstream and terminal filter portions. The borediameter within the intermediate portion may be greater than 3 or 4 or 5mm. For example, it may be between 5 and 7 mm or 6 and 7 mm.

The filter portions may each have a substantially equal axial length,e.g., between 8 and 15 mm, or 9 and 13 mm, e.g., between 10 and 12 mm.The intermediate filter portion have a longer axial length, e.g.,between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g.,around 14 mm.

In a second aspect of the first mode, there is provided a smokingsubstitute system comprising an aerosol-forming article according to thefirst aspect of the first mode and a device comprising a heatingelement.

The device may be a HNB device, i.e., a device adapted to heat but notcombust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. Theheating element may comprise an elongated, e.g., rod, tube-shaped orblade heating element. The heating element may project into or surrounda cavity within the main body for receiving the article/consumabledescribed above.

The device (e.g., the main body) may further comprise an electricalpower supply, e.g., a (rechargeable) battery for powering the heatingelement. It may further comprise a control unit to control the supply ofpower to the heating element.

In a third aspect of the first mode, there is provided a method of usinga smoking substitute system according to the second aspect of the firstmode, the method comprising: inserting the article/consumable into thedevice; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting thearticle/consumable into a cavity within the main body and penetratingthe article/consumable with the heating element upon insertion of thearticle/consumable. For example, the heating element may penetrate theaerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive,a feature or parameter described in relation to any one of the aboveaspects of the first mode may be applied to any other aspect of thefirst mode. Furthermore, except where mutually exclusive, any feature orparameter described herein may be applied to any aspect of the firstmode and/or combined with any other feature or parameter describedherein.

Second Mode: A Consumable Having a Substrate Having a Gathered Web ofPlant Material

At its most general, a second mode of the present disclosure relates toan aerosol-forming article, e.g., a consumable for use in a smokingsubstitute system and particularly, although not exclusively, to aheat-not-burn (HNB) consumable, wherein the article/consumable comprisessubstrate having a gathered web of plant material. The presentdisclosure also relates to a web of plant material, a method for formingthe web of plant material, and a method for forming the article.

Accordingly, in a first aspect of the second mode, there is provided anaerosol-forming substrate comprising a plurality of first elongateshreds of plant material and a plurality of second elongate shreds ofplant material, each first shred having longitudinal edges spaced by afirst transverse width and each second shred having longitudinal edgesspaced by a second transverse width, wherein the first transverse widthis different to the second transverse width.

Providing an aerosol-forming substrate with shreds of different widthsmay allow characteristics of the substrate to be altered by changing thedistribution of the shreds within the substrate. For example, an evendistribution of the first and second shreds within a substrate mayresult in different heat transfer characteristics than if the first andsecond shreds are unevenly distributed throughout the substrate.

Optional features will now be set out. These are applicable singly or inany combination with any aspect of the second mode.

The first shreds may be interspersed with the second shreds in a waythat the first and second shreds are distributed generally evenlythroughout the substrate. That is, the number (and/or weight and/orvolume) of first shreds may be substantially equal to the number (and/orweight and/or volume) of second shreds throughout the aerosol-formingsubstrate.

The first and second shreds may be unevenly distributed throughout thesubstrate. In preferred embodiments, a first region of the substratecomprises a greater proportion (e.g., by number) of first shreds than ofthe second shreds. The first region of the substrate may comprise agreater proportion, by weight, volume and/or by number, of first shredsof the second shreds. The first region may predominantly, or solely,comprise first shred (i.e., the first region may not comprise any secondshreds). The first region may be at, or proximate to, a periphery of thesubstrate.

The aerosol-forming substrate may further comprise a second regioncomprising a greater proportion of second shreds than of the firstshreds. The second region of the substrate may comprise a greaterproportion, by weight, volume and/or number, of second shreds than ofthe first shreds. The second region may predominantly, or solely,comprise second shreds (i.e., the second region may not comprise anyfirst shreds). The second region may be disposed at a central, axialportion of the substrate, which is spaced from a periphery of thesubstrate.

The differences in the composition of the first and second regions mayresult in different (e.g., heat transfer) characteristics at thoseregions. Thus, the regions may be positioned so as to provide a desiredeffect in regards to, e.g., transfer of heat. For example, it may bedesirable to have a consistent temperature across the substrate whenheated. In this case, regions that are proximate to a heating element(when positioned in the substrate) may be formed in such a way that theytransfer heat more rapidly (e.g., to regions that are distal from theheating element).

In preferred embodiments the substrate is cylindrical. In this respect,the first region may extend circumferentially and proximate to acircumferential surface of the cylinder (i.e., such that the firstregion has a generally tubular shape). The second region may extendalong a substantially central axis of the cylinder, (i.e., so as todefine a core of a generally cylindrical shape). In this respect, theproportion of first shreds relative to the second shreds may vary in aradial direction of the substrate. In some cases, wider shreds mayresult in wider air paths (i.e., formed between the shreds) in thesubstrate, which may lead to a cooler portion of the substrate where thewider shreds are located. Where the wider shreds are located at theouter (peripheral) portion of the substrate, the outer portion (andouter surface) of the substrate may be cooler.

Alternatively, or additionally, the proportion of first shreds relativeto the second shreds may vary in an axial direction with respect to thesubstrate. In these embodiments, the first region of the substrate(having a greater proportion of first shreds) and the second region ofthe substrate (having greater proportion of second shreds) will beaxially adjacent one another. For example, the first region may be atthe axial upstream end of the substrate and the second region may be atthe axial downstream end of the substrate.

The variation of the proportion of the first and second shreds (e.g.,radially or axially) may vary gradually, or may vary abruptly.

There may be an intermediate region containing an equal proportion, byweight, volume and/or number of first and second shreds. This may beradially interposed between the radially segregated first and secondregions or axially interposed between the axially segregated first andsecond regions.

In some embodiments, the first transverse width is greater than thesecond transverse width. In other embodiments, the second transversewidth is greater than the first transverse width.

The ratio of the greater of the first and second transverse width to thelesser of the first and second transverse width may be between 1.5:1 and3:1. The ratio may be between 1.5:1 and 2.5:1. Preferably, the ratio is2:1.

The lesser of the first and second transverse width may be between 0.5mm and 2 mm, preferably between 0.8 mm and 1.2 mm, e.g., around 1 mm.The greater of the first and second transverse width may be between 1.5mm and 3 mm, preferably, between 1.8 mm and 2.2 mm, e.g., around 2 mm.

In preferred embodiments the first shreds are aligned substantiallyparallel to one another. In preferred embodiments the second shreds arealigned substantially parallel to one another. The first shreds may bealigned substantially parallel to the second shreds. The first and/orsecond shreds may be oriented so as to extend in a longitudinaldirection of the substrate. In other embodiments, the shreds may be,e.g., crimped across their transverse width and may not be parallel toone another. In some embodiments the shreds may have a random (orgenerally random) orientation in the substrate.

The aerosol-forming substrate may further comprise any number ofpluralities of further shreds having a further transverse widthdifferent to both the first and second transverse widths. In thisrespect, the aerosol forming substrate may comprise any number offurther regions, each further region having a greater proportion offurther shreds.

The aerosol-forming substrate is capable of being heated to release atleast one volatile compound that can form an aerosol.

In order to generate an aerosol, the aerosol-forming substrate comprisesat least one volatile compound that is intended to bevaporized/aerosolized and that may provide the user with a recreationaland/or medicinal effect when inhaled. Suitable chemical and/orphysiologically active volatile compounds include the group consistingof: nicotine, cocaine, caffeine, opiates and opioids, cathine andcathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorinA together with any combinations, functional equivalents to, and/orsynthetic alternatives of the foregoing.

The first, second and further shreds may each comprise at least oneplant material selected from the list including Amaranthus dubius,Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisiavulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean),Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum(wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholziacalifornica (California Poppy), Fittonia albivenis, Hippobromalongiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops),Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus,Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobeliacardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica,Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba(White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passifloraincamata (Passionflower), Pedicularis densiflora (Indian Warrior),Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salviadorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata,Scutellaria lateriflora, Scutellaria nana, Scutellaria species(Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis,Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon),Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum(Mullein), Zamia latifolia (Maconha Brava) together with anycombinations, functional equivalents to, and/or synthetic alternativesof the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may beused. This includes, but is not limited to, flue-cured tobacco, burleytobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco,dark-fired tobacco, perique tobacco and rustica tobacco. This alsoincludes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includesleaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco,tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco,homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobaccoand/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise at least 50 wt % plantmaterial, e.g., at least 60 wt % plant material, e.g., around 65 wt %plant material. The aerosol-forming substrate may comprise 80 wt % orless plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additivesselected from humectants, flavorants, fillers, aqueous/non-aqueoussolvents and binders.

Humectants are provided as vapor generators—the resulting vapor helpscarry the volatile active compounds and increases visible vapor.Suitable humectants include polyhydric alcohols (e.g., propylene glycol(PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG))and their esters (e.g., glycerol mono-, di- or tri-acetate). They may bepresent in the aerosol-forming substrate in an amount between 1 and 50wt %.

The humectant content of the aerosol-forming substrate may have a lowerlimit of at least 1% by weight of the plant material, such as at least 2wt %, such as at least 5 wt %, such as at least 10 wt %, such as atleast 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upperlimit of at most 50% by weight of the plant material, such as at most 40wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-formingsubstrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together thecomponents forming the aerosol-forming substrate. Binders may comprisestarches and/or cellulosic binders such as methyl cellulose, ethylcellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methylcellulose, gums such as xanthan, guar, Arabic and/or locust bean gum,organic acids and their salts such as alginic acid/sodium alginate, agarand pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-formingsubstrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen theaerosol-forming substrate. Fillers may comprise fibrous (non-tobacco)fillers such as cellulose fibers, lignocellulose fibers (e.g., woodfibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-formingsubstrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueoussolvent. In some embodiments, the aerosol forming substrate has a watercontent of between 5 and 10 wt %, e.g., between 6-9 wt % such as between7-9 wt %.

The flavorant may be provided in solid or liquid form. It may includementhol, licorice, chocolate, fruit flavor (including, e.g., citrus,cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobaccoflavor. The flavorant may be evenly dispersed throughout theaerosol-forming substrate or may be provided in isolated locationsand/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantiallycylindrical shape such that the article/consumable resembles aconventional cigarette. It may have a diameter of between 5 and 10 mm,e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may havean axial length of between 10 and 15 mm, e.g., between 11 and 14 mm suchas around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by awrapping layer, e.g., a paper wrapping layer. The wrapping layer mayoverlie an inner foil layer or may comprise a paper/foil laminate (withthe foil innermost).

In a second aspect of the second mode, there is provided anaerosol-forming article comprising an aerosol-forming substrateaccording to the first aspect of the second mode.

The aerosol-forming article is preferably a heat-not-burn (HNB)consumable.

The aerosol-forming substrate may be located at an upstream axial end ofthe article/consumable.

As used herein, the terms “upstream” and “downstream” are intended torefer to the flow direction of the vapor/aerosol, i.e., with thedownstream end of the article/consumable being the mouth end or outletwhere the aerosol exits the article/consumable for inhalation by theuser. The upstream end of the article/consumable is the opposing end tothe downstream end.

The article/consumable may comprise at least one filter element. Theremay be a terminal filter element at the downstream/mouth end of thearticle/consumable.

There may be a plurality of, e.g., two filter elements which may beadjacent one another or which may be spaced apart. Any filter element(s)upstream of the terminal filter element may be at least partly (e.g.,entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filterelement/upstream filter element) may be comprised of cellulose acetateor polypropylene tow. The at least one filter element (e.g., theterminal filter element/upstream filter element) may be comprised ofactivated charcoal. The at least one filter element (e.g., the terminalelement/upstream filter element) may be comprised of paper. The at leastone filter element (e.g., the terminal element/upstream filter element)may be comprised of extruded plant material. The or each filter elementmay be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shapewith a diameter substantially matching the diameter of theaerosol-forming substrate (with or without its associated wrappinglayer). The axial length of the or each filter element may be less than20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g.,between 10 and 12 mm.

The or at least one of the filter element(s) (e.g., the terminal filterelement/upstream filter element) may be a solid filter element. The orat least one of the filter element(s) (e.g., the terminal filterelement/upstream filter element) may be a hollow bore filter element.The or each hollow bore filter may have a bore diameter of between 1 and5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal filter element (at the downstream end of thearticle/consumable) may be joined to the upstream elements forming thearticle/consumable by a circumscribing tipping layer, e.g., a tippingpaper layer. The tipping paper may have an axial length longer than theaxial length of the terminal filter element such that the tipping papercompletely circumscribes the terminal filter element plus the wrappinglayer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filterelement may include a capsule, e.g., a crushable capsule (crush-ball)containing a liquid flavorant, e.g., any of the flavorants listed above.The capsule can be crushed by the user during smoking of thearticle/consumable to release the flavorant. The capsule may be locatedat the axial center of the terminal filter element.

In some embodiments, the article/consumable may comprise anaerosol-cooling element which is adapted to cool the aerosol generatedfrom the aerosol-forming substrate (by heat exchange) before beinginhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-formingsubstrate. For example, it may be between the aerosol-forming substrateand a/the filter element and/or between two filter elements. The aerosolcooling element may be at least partly (e.g., completely) circumscribedby the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics materialselected from the group consisting of polylactic acid (PLA), polyvinylchloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET).The aerosol-cooling element may be formed of a crimped/gathered sheet ofmaterial to form a structure having a high surface area with a pluralityof longitudinal channels to maximize heat exchange and cooling of theaerosol.

The article/consumable may comprise a spacer element that defines aspace or cavity or chamber between the aerosol-forming substrate and thedownstream end of the article/consumable. The spacer acts to allow bothcooling and mixing of the aerosol. It may be provided between theaerosol-forming substrate and a/the filter element and/or between twofilter elements. The spacer element may comprise a tubular element,e.g., a cardboard tube. The spacer element may be at least partly (e.g.,entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm,e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may havean axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or13 and 14 mm, e.g., around 14 mm.

In a third aspect of the second mode, there is provided a smokingsubstitute system comprising an aerosol-forming article according to thesecond aspect of the second mode and a device comprising a heatingelement.

The device may be a HNB device, i.e., a device adapted to heat but notcombust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. Theheating element may comprise an elongated, e.g., rod, tube-shaped orblade heating element. The heating element may project into or surrounda cavity within the main body for receiving the article/consumabledescribed above.

The device (e.g., the main body) may further comprise an electricalpower supply, e.g., a (rechargeable) battery for powering the heatingelement. It may further comprise a control unit to control the supply ofpower to the heating element.

In a fourth aspect of the second mode, there is provided a web of plantmaterial comprising a plurality of first elongate shreds of plantmaterial and a plurality of second elongate shreds of plant material,each first shred having longitudinal edges spaced by a first transversewidth and each second shred having longitudinal edges spaced by a secondtransverse width, wherein the first transverse width is different to thesecond transverse width.

As will be described further below, the web of plant material of thefourth aspect of the second mode may be used to form the aerosol-formingsubstrate of the first aspect of the second mode (and consequently, thearticle of the second aspect of the second mode).

The plant material may comprise at least one plant material selectedfrom the list provided above with respect to the aerosol-formingsubstrate of the first aspect of the second mode.

In preferred embodiments the second shreds are interspersed with thefirst shreds. The distribution of first and second shreds across thetransverse width of the web of plant material may be substantially even.For example, the first and second shreds may be arranged in analternating pattern (e.g., one first shred followed by one second shredetc.). Similarly, a plurality (e.g., two, three, four, etc.) of firstshreds may be followed by one or more (e.g., two, three, four, etc.)second shreds, and this pattern may repeat itself across the transversewidth of the web.

The shreds may alternatively be distributed in a non-even manner. Thefirst and second shreds may also be segregated from one another (i.e.,non-interspersed). For example, the first shreds may be grouped togetherat a first side of the web, and the second shreds may be groupedtogether at a second, opposing, side of the web.

Alternatively, the first shreds may be split into two groups sandwichingthe second shreds at the transverse center of the web. Thus, in someembodiments, the web of plant material may comprise one or more of saidfirst shreds at opposing longitudinal edges of the web, and a pluralityof said second shreds located at a central portion of the web betweenthe longitudinal edges of the web. As is set forth above, the firsttransverse width may be greater than the second transverse width. Thus,the first shreds at the longitudinal edges of the web may be wider thanthe second shreds at the central portion of the web. During manufactureof the web, the web may be passed over a plurality of rollers and, insome cases, there may be some (minor) difference in the transverseposition of the web on those rollers. As a result, the web may bendslightly (in the transverse direction) from one roller to the next. Thiscan put extra tension on the outer portions of the web, at thelongitudinal edges of the web. Hence, the provision of wider (i.e.,first) shreds at the longitudinal edges of the web may help to preventbreakage of the shreds when under this extra tension.

The different arrangements of shreds may result in differences in thestructure of an aerosol-forming substrate when formed from the web ofplant material (e.g., by gathering of the web of plant material). Forexample, a substrate formed from the web of plant material may haveregions in which the proportion of first shreds is greater than theproportion of second shreds (and vice-versa). Similarly, a substrateformed from the web may have regions that only include first shreds, andregions that only include second shreds. In this way, the arrangement ofthe first and second shreds in the web can be selected so as to providea substrate with a particular structure and thus particular (e.g., heattransfer) characteristics.

In some embodiments, the web of material may have a transverse dimensionequal to or less than 200 mm, e.g., equal to or less than 150 mm such asequal or less than 140 mm.

In some embodiments, the web of material may have a transverse dimensionequal to or greater than 100 mm, e.g., greater than 110 mm such asgreater than 120 mm.

The web material may have a transverse dimension of around 130 mm. Theweb material may be formed of 50 shreds of 1 mm transverse width and 50shreds of 2 mm transverse width.

The web material may have a sheet weight greater than or equal to 100g/m², e.g., greater than or equal to 110 g/m² such as greater than orequal to 120 g/m².

The web material may have a sheet weight less than or equal to 300 g/m2,e.g., less than or equal to 250 g/m2 or less than or equal to 200 g/m2.

The web material may have a sheet weight of between 120 and 190 g/m².

In a fifth aspect of the second mode there is provided a method forforming a web of plant material, the method comprising: providing asheet of plant material; and dividing the plant material using aplurality of longitudinally-extending slits to form a plurality of firstelongate shreds of plant material and a plurality of second elongateshreds of plant material, each first shred having longitudinal edgesspaced by a first transverse width and each second shred havinglongitudinal edges spaced by a second transverse width, wherein thefirst transverse width is different to the second transverse width.

In some embodiments the longitudinally extending slits are formed bypassing the sheet of plant material through a pair of interdigitatedtransverse stacks of rotary cutting blades. The rotary cutting bladesare unevenly spaced so as to form the first and second shreds ofrespective different first and second transverse widths.

In some embodiments the plant material may be divided such that the(e.g., wider) first shreds are located and opposing longitudinal edgesof the web and the (e.g., narrower) second shreds are located at acentral portion of the web. The method may comprise passing the web overa plurality of rollers. Where this is the case, the wider first shredsat the longitudinal edges of the web may help the web to withstand extratension imparted on the web by way of transverse movement of the webbetween rollers.

The method of the fifth aspect of the second mode may be used to form aweb of plant material according to the fourth aspect of the second mode.

In a sixth aspect of the second mode there is disclosed a method forforming an aerosol-forming, the method comprising: forming a web ofplant material using the method according to the fifth aspect of thesecond mode; gathering the web of plant material to form a cylindricalrod; cutting the cylindrical rod to form a cylindrical aerosol-formingsubstrate; and circumscribing the aerosol-forming substrate using awrapping layer.

In preferred embodiments the gathering of the web of plant material isperformed so as to form a first region of the aerosol-forming articlecomprising a greater proportion of first shreds than second shreds.

In preferred embodiments gathering of the web of plant material isperformed such that the first region is at, or proximate to, thecircumferential peripheral surface of the cylindrical aerosol-formingsubstrate when formed. For example, the web of plant material may bearranged such that it has a greater proportion of first shreds (i.e.,having a first transverse width) than second shreds (i.e., having asecond transverse width) proximate to its longitudinal surface. Thegathering may be such that the longitudinal surface (and regionsproximate to this surface) form the circumferential peripheral surfaceof the cylindrical rod (and subsequently form the circumferentialsurface of the substrate).

The method may comprise forming a plurality of webs of plant material(e.g., two webs) and may further comprise combining the webs of plantmaterial to form a cylindrical rod. In this respect, the plurality ofwebs of plant material may be gathered together so as to combine them.Each web of plant material may comprise shreds of single width (i.e.,such that the web is formed differently to the method described in thefifth aspect of the second mode), but that width may be different foreach of the plurality of webs of plant material. In that respect, whenthe plurality of webs of plant material are combined to form thecylindrical rod, the rod may comprise a plurality of shreds havingdifferent widths.

In a seventh aspect of the second mode, there is provided a method ofusing a smoking substitute system according to the third aspect of thesecond mode, the method comprising inserting the article/consumable intothe device, and heating the article/consumable using the heatingelement.

In some embodiments, the method comprises inserting thearticle/consumable into a cavity within the main body and penetratingthe article/consumable with the heating element upon insertion of thearticle/consumable. For example, the heating element may penetrate theaerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive,a feature or parameter described in relation to any one of the aboveaspects of the second mode may be applied to any other aspect of thesecond mode. Furthermore, except where mutually exclusive, any featureor parameter described herein may be applied to any aspect of the secondmode and/or combined with any other feature or parameter describedherein.

SUMMARY OF THE FIGURES

So that the invention may be understood, and so that further aspects andfeatures thereof may be appreciated, embodiments illustrating theprinciples of the invention will now be discussed in further detail withreference to the accompanying figures, in which:

FIG. 1 shows a first embodiment of the first mode of an HNB consumable.

FIG. 2 shows a second embodiment of the first mode of an HNB consumable.

FIG. 3 shows a third embodiment of the first mode of an HNB consumable.

FIG. 4 shows the first embodiment of the first mode within a deviceforming an HNB system.

FIG. 5 shows a first embodiment of the second mode of an HNB consumable.

FIG. 6 shows a second embodiment of the second mode of an HNBconsumable.

FIG. 7 shows a third embodiment of the second mode of an HNB consumable.

FIG. 8 shows the first embodiment within a device forming an HNB systemof the second mode.

FIG. 9 shows a first embodiment of the second mode of a substrate thatmay form part of a HNB consumable.

FIG. 10 shows a second embodiment of the second mode of a substrate thatmay form part of a HNB consumable.

FIG. 11 shows an embodiment of the second mode of a shred of plantmaterial.

FIG. 12A shows a first embodiment of the second mode of a web of plantmaterial that may be used together to form a substrate.

FIG. 12B shows a second embodiment of the second mode of a web of plantmaterial that may be used together to form a substrate.

FIG. 13 shows a third embodiment of the second mode of a web of plantmaterial that may be used to form a substrate.

FIG. 14 shows a fourth embodiment of the second mode of a web of plantmaterial that may be used to form a substrate.

DETAILED DESCRIPTION OF THE FIGURES

First Mode: A Consumable Having an Axial Bore Extending from anAerosol-Forming Substrate to the Downstream Axial End of the Article

As shown in FIG. 1, the HNB consumable 1 comprises an aerosol-formingsubstrate 2 at the upstream end 6 of the consumable 1.

The aerosol-forming substrate comprises reconstituted tobacco whichincludes nicotine as a volatile compound.

The aerosol-forming substrate 2 comprises 65 wt % tobacco which isprovided in the form of gathered shreds produced from a sheet ofslurry/paper recon tobacco. The tobacco is dosed with 20 wt % of ahumectant such as propylene glycol (PG) or vegetable glycerin (VG) andhas a moisture content of between 7-9 wt %. The aerosol-formingsubstrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 is formed in a substantially cylindricalshape such that the consumable resembles a conventional cigarette. Ithas diameter of around 7 mm and an axial length of around 12 mm.

The consumable further comprises a filter element 4 formed of celluloseacetate tow and having an axial length of around 36 mm. The filterelement 4 has a substantially cylindrical shape with diameter of thefilter element 4 matching the diameter of the aerosol-forming substrate2. There is a hollow axial bore 5 having a diameter of around 2 mmextending from the downstream axial end 7 of the aerosol-formingsubstrate to the downstream axial end 8 of the consumable 1.

The aerosol-forming substrate 2 and filter element 4 is circumscribed bya paper wrapping layer 3.

FIG. 2 shows a second embodiment of a consumable 1′ which is the same asthat shown in FIG. 1 except that the filter element 4 comprises anupstream filter portion 4 a having an axial length of 10 mm and bore 5 adiameter of 3 mm, an intermediate filter portion 4 b having an axiallength of 14 mm and a bore 5 b diameter of 5 mm and a terminal filterportion 4 c having an axial length of 12 mm and a bore 5 c diameter of 3mm.

There is a stepped change in bore diameter between the three portions 4a, 4 b, and 4 c, and each are integrally combined for form the unitaryfilter element.

FIG. 3 shows a third embodiment of a consumable 1″ which is the same asthe second embodiment except that bore 5 a in the upstream filterportion 4 a has a greater diameter (3 mm) than the bore 5 c in theterminal filter portion 4 c.

FIG. 4 shows the first embodiment inserted into an HNB device 10comprising a rod-shaped heating element 20. The heating element 20projects into a cavity 11 within the main body 12 of the device.

The consumable 1 is inserted into the cavity 11 of the main body 12 ofthe device 10 such that the heating rod 20 penetrates theaerosol-forming substrate 2. Heating of the reconstituted tobacco in theaerosol-forming substrate 2 is effected by powering the heating element(e.g., with a rechargeable battery (not shown)). As the tobacco isheated, moisture and volatile compound (e.g., nicotine) within thetobacco and the humectant are released as a vapor and entrained withinan airflow generated by inhalation by the user at the upstream axial end8 of the consumable.

The axial bore 5 extending from the downstream axial end 7 of thesubstrate to the axial downstream (mouth) end 8 of the article providesa space for mixing and cooling of the vapor/aerosol generated by heatingof the substrate and also provides passage of low resistance to helpreduce condensation and maximize visible vapor.

Second Mode: A Consumable Having a Substrate Having a Gathered Web ofPlant Material

As shown in FIG. 5, the HNB consumable 1 a comprises an aerosol-formingsubstrate 2 a at the upstream end of the consumable 1 a.

The aerosol-forming substrate 2 a comprises reconstituted tobacco whichincludes nicotine as a volatile compound.

The aerosol-forming substrate 2 a comprises 65 wt % tobacco which isprovided in the form of gathered shreds produced from a sheet ofslurry/paper recon tobacco. The tobacco is dosed with 20 wt % of ahumectant such as propylene glycol (PG) or vegetable glycerin (VG) andhas a moisture content of between 7-9 wt %. The aerosol-formingsubstrate further comprises cellulose pulp filler and guar gum binder.

Although not apparent from FIG. 5, the substrate 2 a is formed of aplurality of shreds of plant material. An exemplary portion of a shredof plant material 24 is shown (not to scale) in FIG. 11. The shred ofplant material 24 comprises spaced longitudinal edges 25 a, 25 b and atransverse width W of the shred of plant material 24 is defined betweenthe longitudinal edges 25 a, 25 b. The transverse width W of the shredof plant material 24 is generally consistent for the entire length ofthe shred 24.

The aerosol-forming substrate 2 a comprises a plurality of first shreds24 having a first transverse width W1 and a plurality of second shreds24 having a second transverse width W2 that is different from the firsttransverse width W1. The first and second shreds 24 are distributedevenly throughout the substrate 2 a.

The aerosol-forming substrate 2 a is formed in a substantiallycylindrical shape such that the consumable resembles a conventionalcigarette. It has diameter of around 7 mm and an axial length of around12 mm.

The aerosol-forming substrate 2 a is circumscribed by a paper wrappinglayer 3 a.

The consumable 1 a comprises an upstream filter element 22 a and adownstream (terminal) filter element 26 a. The two filter elements 22 a,26 a and spaced by a cardboard spacer tube 30 a. Both filter elements 22a, 26 a are formed of cellulose acetate tow and wrapped with arespective paper plug layer (not shown).

Both filter elements 22 a, 26 a have a substantially cylindrical shape.The diameter of the upstream filter 22 a matches the diameter of theaerosol-forming substrate 2 a. The diameter of the terminal filterelement 26 a is slightly larger and matches the combined diameter of theaerosol-forming substrate 2 a and the wrapping layer 3 a. The upstreamfilter element 22 a is slightly shorter in axial length than theterminal filter element 26 a at an axial length of 10 mm compared to 12mm for the terminal filter element 26 a.

The cardboard tube spacer 30 a is longer than each of the two filterportions 22 a, 26 a having an axial length of around 14 mm.

Each filter element 22 a, 26 a is a hollow bore filter element with ahollow, longitudinally extending bore. The diameter of the bore in theupstream filter 22 a is slightly larger than the diameter of the bore inthe terminal filter 26 a having a diameter of 3 mm compared to 2 mm forthe terminal filter element 26 a.

The cardboard spacer tube 30 a and the upstream filter portion 22 a arecircumscribed by the wrapping layer 3 a.

The terminal filter element 26 a is joined to the upstream elementsforming the consumable by a circumscribing paper tipping layer 34 a. Thetipping layer 34 a encircles the terminal filter portion and has anaxial length of around 20 mm such that it overlays a portion of thecardboard tube spacer 30 a.

FIG. 6 shows a second embodiment of a consumable 1 a′ which is the sameas that shown in FIG. 5 except that the terminal filter element 26 a isa solid filter element and comprises a crushable capsule 38 a(crush-ball) having a shell wall containing a liquid menthol or cherryor vanilla flavorant. The capsule 38 a is spherical and has a diameterof 3.5 mm. It is positioned within the axial center of the terminalfilter portion 26 a.

FIG. 7 shows a third embodiment of a consumable 1 a″ which is the sameas the first embodiment except that the wrapping layer 3 a does notcompletely circumscribe the cardboard spacer tube 30 a such that thereis an annular gap 42 a between the tipping layer 34 a and the cardboardspacer tube 30 a downstream of the end of the wrapping layer 3 a.

FIG. 8 shows the first embodiment inserted into an HNB device 10 acomprising a rod-shaped heating element 20 a (shown in dashed lines).The heating element 20 a projects into a cavity 11 a within the mainbody 12 a of the device 10 a.

The consumable 1 a is inserted into the cavity 11 a of the main body 12a of the device 10 a such that the heating rod penetrates theaerosol-forming substrate 2 a. Heating of the reconstituted tobacco inthe aerosol-forming substrate 2 a is effected by powering the heatingelement 20 a (e.g., with a rechargeable battery (not shown)). As thetobacco is heated, moisture and volatile compound (e.g., nicotine)within the tobacco and the humectant are released as a vapor andentrained within an airflow generated by inhalation by the user at theterminal filter portion 26 a.

As the vapor cools within the upstream filter element 22 a and thecardboard spacer tube 30 a, it condenses to form an aerosol containingthe volatile compounds for inhalation by the user.

FIG. 9 depicts an embodiment of an aerosol-forming substrate 2 a′. Asmay be apparent, the substrate 2 a′ may form a part of any one of theconsumables described above and shown in FIGS. 5 to 8. The substrate 2a′ comprises a generally cylindrical form having a circumferentialsurface 46 extending between first (upstream) 50 and second (downstream)54 ends. Although not apparent from FIG. 9, the substrate 2 a′ is formedof a plurality of shreds of plant material 24. An exemplary portion of ashred of plant material 24 is shown (not to scale) in FIG. 11. The shredof plant material 24 comprises spaced longitudinal edges 25 a, 25 b anda transverse width W of the shred of plant material 24 is definedbetween the longitudinal edges 25 a, 25 b. The transverse width W of theshred of plant material 24 is generally consistent for the entire lengthof the shred 24.

Returning to FIG. 9, the plurality of longitudinally aligned shreds ofplant material 24 (that form the substrate 2 a′) comprises first shreds24 and second shreds 24. The first shreds 24 have a first transversewidth W1 and the second shreds 24 have a second transverse width W2 thatis different from the first transverse width W1. In the presentlyillustrated embodiment, the first and second shreds 24 are notdistributed evenly throughout the substrate 2 a′. Rather, the substrate2 a′ comprises first region 58 and second region 62 that differ withrespect to their distribution of first and second shreds 24.

The first region 58 extends circumferentially at a periphery of thesubstrate 2 a′ (i.e., at the circumferential surface 46), so as to havea donut shaped transverse cross-sectional profile. This first region 58has a greater proportion (e.g., by volume, number, and/or weight) offirst shreds 24 than of the second shreds 24. The first region 58 may,for example, only include first shreds 24. Where the first transversewidth W1 is larger than the second transverse width W2, the first region58 is predominantly formed of larger-width shreds.

The second region 62 extends along a central longitudinal axis of thesubstrate 2 a′ so as to define a central 25 core of the substrate 2 a′(surrounded by the first region). In contrast to the first region 58,the second region 62 comprises a greater proportion (e.g., by volume,number and/or weight) of second shreds 24 than of the first shreds 24.The second region 62 may only include second shreds 24. Assuming againthat first transverse width W1 is larger than the second transversewidth W2, the second region 62 is predominantly made up of smaller-widthshreds.

By having larger width shreds at its periphery, and smaller width shredsat its center, the substrate 2 a′ may have different heat transfercharacteristics than a substrate containing a single shred type. Forexample, the second region 62 may have a higher rate of heat transferthan the first region 58.

FIG. 10 depicts a further embodiment of a substrate 2 a″ that againcomprises a first region 58 having a greater proportion of first shreds24 (comprising a first transverse width W1) and a second region 62having a greater proportion of second shreds 24. However, in this case,the regions 58, 62 are arranged so as to be axially adjacent to oneanother. Thus, the proportion of first and second shreds 24 variesaxially rather than radially (as is the case with the embodiment shownin FIG. 9).

FIGS. 12A and 12B depict webs of plant material 66, 66′ for forming anaerosol forming substrate. Each of the webs 66, 66′ comprises aplurality of longitudinally extending shreds. Each web 66, 66′ is formedof a sheet of homogenized tobacco, e.g., a sheet of paper recon orslurry recon tobacco which is slit by passing it longitudinally betweena pair of interdigitated transverse stacks of spaced apart rotarycutting blades. The blades cut a plurality of longitudinally-extendingslits 70 a, 70 b, 70 c, etc. in the sheet, thus forming the web 66, 66′.As is indicated by the dashed lines, each web 66, 66′ may extendindefinitely in the longitudinal direction.

The web 66 shown FIG. 12A comprises first shreds 74 a, 74 b, 74 c, etc.that each have a transverse width W1 of 1 mm. Such shreds 74 a, 74 b, 74c may be formed by interdigitated transverse stacks of rotary cuttingblades (as discussed above) spaced apart by 1 mm. On the other hand, theweb 66′ shown in FIG. 12B comprises second shreds 78 a, 78 b, 78 c, etc.that each have a transverse width W2 of 2 mm. Again, such shreds 78 a,78 b, 78 c may be formed by interdigitated transverse stacks of rotarycutting blades (as discussed above) spaced apart by 2 mm.

As will be discussed in more detail below, the shreds of the webs 66,66′ may gathered to form an aerosol forming substrate. In this respect,the aerosol-forming substrate would comprise a plurality of first shredsof 1 mm transverse width W1 (from the web of FIG. 12A) and a pluralityof second shreds of 2 mm transverse width W2 (from the web of FIG. 12B).

FIG. 13 shows a further embodiment of a web of plant material 66″comprising first and second shreds. The first shreds 74 a, 74 b, 74 c,etc. have a transverse width W1 of 1 mm and the second shreds 78 a, 78b, 78 c, etc. have a transverse width W2 of 2 mm. As is apparent fromFIG. 13, the first shreds 74 a, 74 b, 74 c are interspersed with thesecond shreds 78 a, 78 b, 78 c. In particular, the pattern of shreds(progressing transversely across the web) alternates between a singlesecond shred 78 a and two first shreds 74 a, 74 b.

This web 66″ may also be formed by way of interdigitated transversestacks of spaced apart rotary cutting blades (as discussed above), butin this case the cutting blades are not evenly spaced. Rather, thecutting blades are arranged in groups of three 1 mm spaced cuttingblades, with the groups of cutting blades spaced from one another by 2mm.

Like the previously described webs 66, 66′, this web 66″ can be gatheredto form an aerosol-forming substrate. However, rather than forming thissubstrate from two separate webs, only a single web 66″ of the presentembodiment is required to form the aerosol-forming substrate comprisingfirst shreds 74 a, 74 b, 74 c and second shreds 78 a, 78 b, 78 c of twodifferent transverse widths W1, W2. As may be apparent from FIG. 13, anaerosol-forming substrate formed from the present web 66″ would have(approximately) an even distribution (e.g., by weight or volume) ofshreds 74 a, 74 b, 74 c of 1 mm transverse width and shreds 78 a, 78 b,78 c of 2 mm transverse width.

FIG. 14 shows a further embodiment of a web 66′″ of plant material. Likethe embodiment shown in FIG. 13, this embodiment comprises first andsecond shreds of 1 mm transverse width and 2 mm transverse widthrespectively. However, the distribution of the first and second shredsis different to that previously described. In the present embodiment thesecond shreds 78 a, 78 b, 78 c are distributed at the longitudinal edges82 of the web 66′″ and the first shreds 74 a, 74 b, 74 c are sandwichedbetween the second shreds 78 a, 78 b, 78 c at a central region of theweb 66′″. Again, this web 66′″ may also be formed by way ofinterdigitated transverse stacks of spaced apart rotary cutting blades.In this case, there are two groups of two 2 mm spaced cutting blades(for forming the second shreds) and a single group of 1 mm spacedcutting blades (for forming the first shreds) disposed intermediate thetwo 2 mm groups and spaced from those groups by 2 mm. When this web 66′″is gathered the first shreds will be bundled together in a core regionat the axial center of the substrate 2 a″.

The features disclosed in the foregoing description, or in the followingclaims, or in the accompanying drawings, expressed in their specificforms or in terms of a means for performing the disclosed function, or amethod or process for obtaining the disclosed results, as appropriate,may, separately, or in any combination of such features, be utilized forrealizing the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplaryembodiments described above, many equivalent modifications andvariations will be apparent to those skilled in the art when given thisdisclosure. Accordingly, the exemplary embodiments of the invention setforth above are considered to be illustrative and not limiting. Variouschanges to the described embodiments may be made without departing fromthe scope of the invention.

For the avoidance of any doubt, any theoretical explanations providedherein are provided for the purposes of improving the understanding of areader. The inventors do not wish to be bound by any of thesetheoretical explanations.

Any section headings used herein are for organizational purposes onlyand are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unlessthe context requires otherwise, the words “have”, “comprise”, and“include”, and variations such as “having”, “comprises”, “comprising”,and “including” will be understood to imply the inclusion of a statedinteger or step or group of integers or steps but not the exclusion ofany other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” one particular value, and/or to “about” anotherparticular value. When such a range is expressed, another embodimentincludes from the one particular value and/or to the other particularvalue. Similarly, when values are expressed as approximations, by theuse of the antecedent “about,” it will be understood that the particularvalue forms another embodiment. The term “about” in relation to anumerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer toembodiments of the invention that may provide certain benefits undersome circumstances. It is to be appreciated, however, that otherembodiments may also be preferred under the same or differentcircumstances. The recitation of one or more preferred embodimentstherefore does not mean or imply that other embodiments are not useful,and is not intended to exclude other embodiments from the scope of thedisclosure, or from the scope of the claims.

1. An aerosol-forming article comprising: an aerosol-forming substrate; and a filter element having a hollow bore extending from the downstream axial end of the substrate to the downstream axial end of the article.
 2. An article according to claim 1 wherein the article is a heat not burn (HNB) consumable.
 3. An article according to claim 1 or 2 wherein the axial length of the filter element is between 25 and 45 mm.
 4. An article according to any one of claims 1-3 wherein the hollow bore through the filter element is uniform along its axial length.
 5. An article according to any one of claims 1 to 3 wherein the hollow bore through the filter element varies along the axial length.
 6. An article according to claim 5 wherein the filter element comprises an upstream filter portion and a terminal filter portion and the bore diameter of the upstream filter portion is greater than the bore diameter of the terminal filter portion.
 7. An article according to claim 5 wherein the filter element comprises an upstream filter portion and a terminal filter portion and the bore diameter of the upstream filter portion is equal to the bore diameter of the terminal filter portion.
 8. An article according to claim 6 or 7 further comprising a filter portion axially interposed and adjacent the upstream and terminal filter portions.
 9. An article according to claim 8 wherein the diameter of the bore within the intermediate portion is larger than the diameter in both the upstream and terminal filter portions.
 10. An article according to claim 8 or 9 wherein the intermediate filter portion has a greater axial length than the upstream and terminal filter portions.
 11. A system comprising a smoking substitute article according to any one of claims 1-10, and a device comprising a heating element.
 12. A system according to claim 11 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 13. A method of using the system according to claim 11 or 12, the method comprising: inserting the article into the device; and heating the article using the heating element.
 14. A method according to claim 13 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 15. An aerosol-forming substrate comprising a plurality of first elongate shreds of plant material and a plurality of second elongate shreds of plant material, each first shred having longitudinal edges spaced by a first transverse width and each second shred having longitudinal edges spaced by a second transverse width, wherein the first transverse width is different to the second transverse width.
 16. An aerosol forming substrate according to claim 15 wherein a first region of the substrate comprises a greater proportion of first shreds than second shreds.
 17. An aerosol-forming substrate according to claim 16 wherein the first region is disposed at a periphery of the substrate.
 18. An aerosol-forming substrate according to any one of claims 15-17, wherein a second region of the substrate comprises a greater proportion of second shreds than of the first shreds.
 19. An aerosol-forming substrate according to claim 18 wherein the second region is disposed at a central portion of the substrate, which is spaced from a periphery of the substrate.
 20. An aerosol-forming substrate according to any one of claims 15-19 that is cylindrical and the proportion of first shreds to second shreds varies in a radial direction.
 21. An aerosol-forming substrate according to any one of claims 15-20 wherein the ratio of the greater of the first and second transverse width to the lesser of the first and second transverse width may is between 1.5:1 and 3:1.
 22. An aerosol-forming substrate according to claim 21 wherein the lesser of the first and second transverse width is between 0.6 mm and 1.4 mm and the greater of the first and second transverse width is between 1.6 mm and 2.4 mm.
 23. An aerosol-forming substrate according to any one of claims 15-22, wherein the first and second shreds are aligned substantially parallel to one another.
 24. An aerosol-forming article comprising an aerosol-forming substrate according to any one of claims 15-23.
 25. An aerosol-forming article according to claim 24 wherein the article is a heat-not-burn (HNB) consumable.
 26. A smoking substitute system comprising an aerosol-forming article according to claim 24 or 25 and a device comprising a heating element.
 27. A system according to claim 26 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 28. A web of plant material comprising a plurality of first elongate shreds of plant material and a plurality of second elongate shreds of plant material, each first shred having longitudinal edges spaced by a first transverse width and each second shred having longitudinal edges spaced by a second transverse width, wherein the first transverse width is different to the second transverse width.
 29. A web of plant material according to claim 28 comprising one or more of said first shreds at opposing longitudinal edges of the web, and a plurality of said second shreds located at a central portion of the web between the longitudinal edges of the web.
 30. A method for forming a web of plant material, the method comprising: providing a sheet of plant material; dividing the plant material using a plurality of longitudinally-extending slits to form a plurality of first elongate shreds of plant material and a plurality of second elongate shreds of plant material, each first shred having longitudinal edges spaced by a first transverse width and each second shred having longitudinal edges spaced by a second transverse width, wherein the first transverse width is different to the second transverse width.
 31. A method according to claim 30 wherein the longitudinally-extending slits are formed by passing the sheet of plant material through a pair of interdigitated transverse stacks of rotary cutting blades wherein the rotary cutting blades are unevenly spaced so as to form the first and second shreds of respective first and second transverse widths.
 32. A method for forming an aerosol forming article, the method comprising: forming a web of plant material using the method according to claim 29 or 30; gathering the web of plant material to form a cylindrical rod; cutting the cylindrical rod to form a cylindrical aerosol-forming substrate; and circumscribing the aerosol-forming substrate using a wrapping layer.
 33. A method according to claim 32 wherein the gathering of the web of plant material is performed so as to form a first region comprising a greater proportion of first shreds than second shreds.
 34. A method according to claim 33 wherein the first region is at, or proximate to the circumferential peripheral surface of the cylindrical aerosol-forming substrate when formed. 